B 1000 - en Gear Units: Operating and Assembly Instructions

B 1000 – en
Gear units
Operating and Assembly Instructions
Gear units – Operating and Assembly Instructions
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Read the operating and installation instructions
Read this operating and installation manual carefully prior to performing any work on or putting the
gear unit into operation. Always observe the instructions in this operating and assembly manual.
Keep this operating and installation manual in the vicinity of the gear unit so that it is available if
required.
Please also note the following documents:
• Gear unit catalogues (G1000, G1012, G1014, G1035, G1050, G2000),
• Operating and maintenance instructions for the electric motor,
• Operating instructions for equipment which is attached or provided.
Please contact Getriebebau NORD GmbH & Co. KG if you require further information.
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2 B 1000 en-5018
Documentation
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Documentation
Designation: B 1000
Material number: 6052802
Series: Gear units and geared motors
Type series:
Gear unit types: Helical gear units
NORDBLOC helical gear units
Standard helical gear units
Parallel shaft gear units
Bevel gear units
Helical worm gear units
MINIBLOC worm gear units
UNIVERSAL worm gear units
Version list
Title, Order Comments
Date number
B 1000, 6052802 / -
February 2013 0713
B 1000, 6052802 / • General corrections
September 2014 3814
B 1000, 6052802 / • New gear unit types SK 10382.1 + SK 11382.1
April 2015 1915
March 2016 0916 • New bevel gear units SK 920072.1 + SK 930072.1
September 2016 3816 • New helical gear units SK 071.1, SK 171.1, SK 371.1, SK 571.1,
SK 771.1;
B 1000 June 6052802 / • General corrections
2018 2518 • New parallel shaft gear units SK 0182.1, SK 0282.1, SK 1282.1,
SK 1382,1
• New worm gear unit SK 02040.1
B 1000 December 6052802 / • General corrections
2018 5018 • Revision of safety and warning information
• New parallel shaft gear units NORDBLOC SK 871.1, SK 971.1,
SK 1071.1
Table 1: Version list B 1000

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B 1000 en-5018 3
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Copyright notice
As an integral component of the device described here, this document must be provided to all
users in a suitable form.
Any editing or amendment or other utilisation of the document is prohibited.
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Publisher
Getriebebau NORD GmbH & Co. KG
Getriebebau-Nord-Straße 1 • 22941 Bargteheide, Germany • http://www.nord.com/
Fon +49 (0) 45 32 / 289-0 • Fax +49 (0) 45 32 / 289-2253
Member of the NORD DRIVESYSTEMS Group

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4 B 1000 en-5018
Publisher
B 1000 en-5018 5
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Table of Contents
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1 Safety information ..................................................................................................................................... 10

1.1 Intended use .................................................................................................................................... 10
1.2 Do not make any modifications. ....................................................................................................... 10
1.3 Performing inspection and maintenance work ................................................................................. 10
1.4 Personnel qualification ..................................................................................................................... 10
1.5 Safety for particular activities ........................................................................................................... 11
1.5.1 Check for transport damage ............................................................................................... 11
1.5.2 Safety information for installation and maintenance ........................................................... 11
1.6 Hazards............................................................................................................................................ 11
1.6.1 Hazards when lifting ........................................................................................................... 11
1.6.2 Hazards due to rotating parts ............................................................................................. 11
1.6.3 Hazards due to high or low temperatures ........................................................................... 11
1.6.4 Hazards due to lubricants and other substances ................................................................ 12
1.6.5 Hazards due to noise.......................................................................................................... 12
1.6.6 Hazards due to pressurised coolants ................................................................................. 12
1.7 Explanation of markings ................................................................................................................... 13
2 Description of gear units .......................................................................................................................... 14
2.1 Type designations and gear unit types............................................................................................. 14
2.2 Type plate ........................................................................................................................................ 16
3 Assembly instructions, storage, preparation, installation .................................................................... 17
3.1 Transporting the gear unit ................................................................................................................ 17
3.2 Storage ............................................................................................................................................ 17
3.3 Long-term storage ............................................................................................................................ 17
3.4 Preparing for installation .................................................................................................................. 19
3.5 Installing the gear unit ...................................................................................................................... 21
3.6 Fitting hubs on the gear shafts ......................................................................................................... 22
3.7 Fitting push-on gear units................................................................................................................. 23
3.8 Fitting shrink discs............................................................................................................................ 26
3.9 Fitting the covers .............................................................................................................................. 27
3.10 Fitting the covers .............................................................................................................................. 27
3.11 Fitting a standard motor ................................................................................................................... 28
3.12 Fitting the cooling coil to the cooling system .................................................................................... 30
3.13 External oil-air cooler ....................................................................................................................... 31
3.13.1 Assembling the cooling system .......................................................................................... 31
3.13.2 Oil-air cooler electrical connection ...................................................................................... 31
3.14 Installation of an oil expansion tank, Option OA............................................................................... 31
3.15 Subsequent paintwork...................................................................................................................... 32
4 Commissioning ......................................................................................................................................... 33
4.1 Check the oil level ............................................................................................................................ 33
4.2 Activating the automatic lubricant dispenser .................................................................................... 33
4.3 Operation with lubricant cooling ....................................................................................................... 34
4.4 Running-in time for the worm gear unit ............................................................................................ 35
4.5 Checklist .......................................................................................................................................... 35
5 Service and maintenance ......................................................................................................................... 36
5.1 Service and Maintenance Intervals .................................................................................................. 36
5.2 Service and Maintenance Work ....................................................................................................... 37
6 Disposal ..................................................................................................................................................... 41
7 Appendix .................................................................................................................................................... 42
7.1 Versions and maintenance............................................................................................................... 42
7.2 Lubricants ........................................................................................................................................ 57
7.3 Lubricant quantities .......................................................................................................................... 60
7.4 Torque values .................................................................................................................................. 68
6 B 1000 en-5018
Table of Contents
7.5 Troubleshooting ............................................................................................................................... 69
7.6 Leakage and leak-tightness ............................................................................................................. 70
7.7 Repair information ............................................................................................................................ 71
7.7.1 Repairs ............................................................................................................................... 71
7.7.2 Internet information............................................................................................................. 71
7.8 Warranty .......................................................................................................................................... 71
7.9 Abbreviations ................................................................................................................................... 72
B 1000 en-5018 7
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List of illustrations
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Figure 1: Type plate (example) with explanation of type plate fields ..................................................................... 16
Figure 2: Activating the vent plug .......................................................................................................................... 20
Figure 3: Activating the vent plug .......................................................................................................................... 20
Figure 4: Removing the vent plug and fitting the special pressure vent................................................................. 20
Figure 5: Example of a simple pulling device ........................................................................................................ 22
Figure 6: Correct assembly of drive elements ....................................................................................................... 22
Figure 7: Applying lubricant to the shaft and the hub............................................................................................. 23
Figure 8: Removing the factory-fitted closing cap .................................................................................................. 24
Figure 9: Gear unit mounted to shaft with a shoulder using the fastening element ............................................... 24
Figure 10: Gear unit mounted to shaft without a shoulder using the fastening element ........................................ 24
Figure 11: Dismantling using dismantling device ................................................................................................... 24
Figure 12: Mounting the rubber buffer (Option G or VG) on parallel shaft gear units ............................................ 25
Figure 13: Attaching the torque support on bevel gear and worm gear units ........................................................ 25
Figure 14: Hollow shaft with shrink disc ................................................................................................................. 26
Figure 15: Fitting the covers, Option SH, Option H, and Option H66..................................................................... 27
Figure 16: Removal and fitting of the cover cap .................................................................................................... 27
Figure 17: Fitting the coupling onto the motor shaft - various types of coupling .................................................... 29
Figure 18: Cooling cover ....................................................................................................................................... 30
Figure 19: Connecting the cooling system ............................................................................................................. 31
Figure 20: Installing the expansion tank ................................................................................................................ 32
Figure 21: Activating the automatic lubricant dispenser with standard motor mounting ........................................ 33
Figure 22: Adhesive label ...................................................................................................................................... 34
Figure 23: Checking the oil level with a dipstick .................................................................................................... 38
Figure 24: Replacing the automatic lubricant dispenser with standard motor mounting ........................................ 39
Figure 25: Oil level check with oil level tank .......................................................................................................... 43
8 B 1000 en-5018
List of tables
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List of tables
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Table 1: Version list B 1000 ..................................................................................................................................... 3

Table 2: Type designations and gear unit types .................................................................................................... 15
Table 3: Disposal of materials ............................................................................................................................... 41
Table 4: Roller bearing greases............................................................................................................................. 57
Table 5: Lubricant table ......................................................................................................................................... 59
Table 6: Lubricant quantities for helical gear units................................................................................................. 61
Table 7: Lubricant quantities for NORDBLOC ....................................................................................................... 62
Table 8: Lubricant quantities for NORDBLOC helical gear units ........................................................................... 63
Table 9: Lubricant quantities for standard helical gear units .................................................................................. 64
Table 10: Lubricant quantities for parallel shaft gear units .................................................................................... 65
Table 11: Lubricant quantities for bevel gear units ................................................................................................ 66
Table 12: Lubricant quantities for helical worm gear units ..................................................................................... 67
Table 13: Torque values ........................................................................................................................................ 68
Table 14: Overview of malfunctions....................................................................................................................... 69
Table 15: Definition of leaks according to DIN 3761 .............................................................................................. 70
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B 1000 en-5018 9
1 Safety information
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1.1 Intended use

These gear units are used to transmit and transform rotary movements. They are intended for use as
part of a drive system in commercially used plant and machinery. The gear units must not be operated
until it has been established that the plant or machinery can be safely operated with the gear unit. The
plant or machinery must comply with the local laws and regulations and all applicable health and
safety requirements must be fulfilled. In particular, the Machinery Directive 2006/42/EC for the
particular field of application must be observed.
The gear units may not be used in environments in which an explosive atmosphere can occur.
The gear units must only be used according to the information in the technical documentation from
Getriebebau NORD GmbH & Co. KG. Damage to the gear unit may result if the gear unit is not used
as intended and according to the information in the operating and assembly manual This may also
result in personal injury.
The foundation or the gear unit fastening must be appropriately designed for the weight and torque. All
of the fastenings provided must be used.
Some gear units are equipped with a cooling coil. These gear units may only be operated if the cooling
circuit is connected and in operation.
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1.2 Do not make any modifications.

Do not make any modifications to the gear unit. Do not remove any protective devices.
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1.3 Performing inspection and maintenance work

Due to lack of maintenance and damage, malfunctions may occur which can result in personal injury.
• Carry out all servicing and maintenance work at the specified intervals.
• Also note that servicing is necessary after long storage periods prior to commissioning.
• Do not operate damaged gear units. The gear unit must not have any leaks.
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1.4 Personnel qualification

All transport, storage, installation, commissioning and maintenance work must be carried out by
qualified specialist personnel.
Qualified specialist personnel are persons who have the training and experience to recognise and
avoid any possible risks.
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10 B 1000 en-5018
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1.5 Safety for particular activities

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1.5.1 Check for transport damage

Transport damage may cause malfunctions of the gear unit, which may cause personal injury. Oil
which escapes due to leaks may cause a slipping hazard.
• Check the packaging and the gear unit for transport damage.
• Do not operate damaged gear units.
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1.5.2 Safety information for installation and maintenance

Before starting work on the gear unit disconnect the drive from the power supply and secure it against
accidental switch-on. Allow the gear unit to cool down. Depressurise the cooling circuit lines.
Damaged or defective components, attachment adapters, flanges and covers may have sharp edges.
Wear work gloves and work clothing.
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1.6 Hazards
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1.6.1 Hazards when lifting

Persons may be injured by falling or swinging gear units. Therefore also observe the following
information:
• Cordon off a wide area around the hazard area. Pay attention to adequate space for avoiding
swinging loads.
• Never stand under suspended loads.
• Select lifting gear and transport equipment according to the weight of the gear unit. The weight of
the gear unit can be obtained from the type plate.
• Only lift the gear units by the eyebolts which are provided. The eyebolts must be fully screwed in.
Only pull on the eyebolts vertically, never cross-wise or at an angle. Only use the eyebolts to lift the
gear unit without other components. The eyebolts are not designed for lifting the gear unit with
attachments. Use the eyebolts on both the gear unit and the motor to lift a geared motor.
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1.6.2 Hazards due to rotating parts

Rotating parts cause a risk of entanglement. Therefore provide a contact guard. In addition to shafts,
this also applies to fans as well as drives and drive elements such as belt drives, chain drives, shrink
discs and couplings.
For test operation do not switch on the drive without an installed drive element or secure the parallel
key.
Take possible run-on of the machine into consideration for the design of protective guards.
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1.6.3 Hazards due to high or low temperatures

The gear unit may heat up to 90 °C during operation. Touching hot surfaces or contact with hot oil may
result in burns. At very low ambient temperatures freezing may occur on contact.
• Only touch the gear unit when wearing gloves after operation or at very low ambient temperatures.
• Before starting maintenance work, allow the gear unit to cool down sufficiently after operation.
• Provide a contact guard if there is a risk that persons may touch the gear unit when it is in
operation.
• Bursts of hot oil mist may be emitted from the pressure vent screw during operation. Provide a
suitable guard so that persons cannot be injured by this.
B 1000 en-5018 11
• Do not place any flammable materials on the gear unit.
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1.6.4 Hazards due to lubricants and other substances

Chemical substances which are used with the gear unit may be toxic. Eye injuries may result if these
substances enter the eyes. Lubricants and adhesives may cause skin irritation.
Oil mist may escape when vent screws are opened.
Due to lubricants and conservation materials, gear units may be slippery and slip out of the hands.
There is a slipping hazard from spilled lubricants.
• When working with chemical substances wear chemical-resistant gloves and work clothing. Wash
your hands after working.
• Wear protective goggles if there is a possibility of splashed chemicals, for example when filling oil
or during cleaning work.
• If chemicals enter the eyes, rinse with large amounts of cold water immediately. Consult a
physician in case of symptoms.
• Observe the safety data sheets for the chemicals. Keep the safety data sheets in the vicinity of the
gear unit.
• Collect spilled lubricants immediately with a binding agent.
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1.6.5 Hazards due to noise

Some gear units or attached components may cause hazardous noise levels during operation. Wear
hearing protection if work has to be carried out close to such gear units.
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1.6.6 Hazards due to pressurised coolants

The cooling system is under high pressure. Damage or opening a cooling line which is under pressure
may result in injury. Depressurise the cooling circuit before working on the gear unit.
12 B 1000 en-5018
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1.7 Explanation of markings
DANGER
Indicates an immediate danger, which may result in death or very serious injury if it is not avoided.
WARNING
Indicates a dangerous situation, which may result in death or serious injury if it is not avoided.
CAUTION
Indicates a dangerous situation, which may result in minor injuries if it is not avoided.
NOTICE
Indicates a situation, which may result in damage to the product or its environment if it is not avoided.
Information
Indicates hints for use and especially important information to ensure reliability of operation.
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B 1000 en-5018 13
2 Description of gear units

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2.1 Type designations and gear unit types
Gear unit types / Type designations

Helical gear units
SK 11E, SK 21E, SK 31E,SK 41E, SK 51E (1-stage)
SK 02, SK 12, SK 22, SK 32, SK 42, SK 52, SK 62N (2-stage)
SK 03, SK 13, SK 23, SK 33N, SK 43, SK 53 (3-stage)
SK 62, SK 72, SK 82, SK 92, SK 102 (2-stage)
SK 320, SK 172, SK 272, SK 372, SK 472, SK 572, SK 672, SK 772, SK 872, SK 972 (2-stage)
SK 273, SK 373, SK 473, SK 573, SK 673, SK 773, SK 873, SK 973 (3-stage)
SK 071.1, SK 371.1, SK 571.1, SK 771.1, SK 871.1, SK 971.1, SK 1071.1 (1-stage)
SK 072.1, SK 172.1, SK 372.1, SK 572.1, SK 672.1, SK 772.1, SK 872.1, SK 972.1 (2-stage)
SK 373.1, SK 573.1, SK 673.1, SK 773.1, SK 873.1, SK 973.1 (3-stage)
SK 0, SK 01, SK 20, SK 25, SK 30, SK 33 (2-stage)
SK 0182NB, SK 0182.1, SK 0282NB, SK 0282.1, SK 1282, SK 1282.1, SK 2282, SK 3282, SK 4282, SK 5282,
SK 0182.1, SK 0282.1, SK 1382NB, SK 1382.1, SK 2382, SK 3382, SK 4382, SK 5382, SK 6382, SK 7382,
SK 8382, SK 9382, SK 10382, SK 10382.1, SK 11382, SK 11382.1, SK 12382 (3-stage)
Bevel gear units
SK 92072, SK 92172, SK 92372, SK 92672, SK 92772;
SK 920072.1, SK 92072.1, SK 92172.1, SK 92372.1, SK 92672.1, SK 92772.1, SK 930072.1. SK 93072.1,
SK 93172.1, SK 93372.1, SK 93672.1, SK 93772.1 (2-stage)
SK 9012.1, SK 9016.1, SK 9022.1, SK 9032.1, SK 9042.1, SK 9052.1, SK 9062.1, SK 9072.1, SK 9082.1,
SK 9086.1, SK 9092.1, SK 9096.1 (3-stage)
SK 9013.1, SK 9017.1, SK 9023.1, SK 9033.1, SK 9043.1, SK 9053.1 (4-stage)
SK 02040, SK 02040.1, SK 02050, SK 12063, SK 12080, SK 32100, SK 42125 (2-stage)
MINIBLOC worm gear units
SK 1S32, SK 1S40, SK 1S50, SK 1S63, SK 1SU..., SK 1SM31, SK 1SM40, SK 1SM50, SK 1SM63 (1-stage)
SK 2S32NB, SK 2S40NB, SK 2S50NB, SK 2S63NB, SK 2SU…, SK 2SM40, SK 2SM50, SK 2SM63 (2-stage)
14 B 1000 en-5018
2 Description of gear units
Gear unit types / Type designations
UNIVERSAL worm gear units
SK 1SI31, SK 1SI40, SK 1SI50, SK 1SI63, SK 1SI75,
SK 1SIS31, …, SK 1SIS75,
SK 1SID31, …, SK 1SID63,
SK 1SMI31, …, SK 1SMI75,
SK 1SMID31, …, SK 1SMID63,
SK 1SIS-D31, …, SK 1SIS-D63 (1-stage),
SK 2SMID40, SK 2SMID50, SK 2SMID63, SK 2SID40, …, SK 2SID63 (2-stage)
Versions / Options
- Foot mounting with solid shaft D Torque support IEC Standard IEC motor mounting
A Hollow shaft version K Torque bracket NEMA Standard NEMA motor
attachment
V Solid shaft version S Shrink disc W With free drive shaft
L Solid shaft both sides VS Reinforced shrink disc VI Viton radial seals
Z Output flange B14 EA Hollow shaft with internal spline OA Oil expansion tank
F Output flange B5 G Rubber buffer OT Oil level tank
X Foot mounting VG Reinforced rubber buffer SO1 Synthetic oil ISO VG 220
XZ Base and output flange B14 R Back stop CC Housing cover with cooling spiral
XF Base and output flange B5 B Fastening element
AL Reinforced axial output bearings H Covering cap as contact guard DR Pressure venting
5 Reinforced output shaft H66 Covering cap IP66 H10 Modular helical pre-stage
(Standard helical gear units)
V Reinforced drive VL Reinforced bearings /31 Worm pre-stage
(Standard helical gear units)
VL2 Agitator version /40 Worm pre-stage
VL3 Drywell agitator version
Table 2: Type designations and gear unit types
Double gear units consist of two single gear units. They are to be treated as per the instructions in this
manual, i.e. as two individual gear units.
Type designation for double gear units: e. g. SK 73 / 22 (consisting of single gear units SK 73 and
SK 22).
B 1000 en-5018 15
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2.2 Type plate

Explanation
1 Matrix – Barcode
2 NORD gear unit type
3 Operating mode
4 Year of manufacture
5 Serial number
Rated torque of gear unit
6
output shaft
7 Drive power
Weight according to ordered
8
version
9 Overall gear unit ratio
10 Installation orientation
Rated speed of gear unit
11
output shaft
Lubricant type,
12
viscosity and quantity
13 Customer’s part number
14 Operating factor
Figure 1: Type plate (example) with explanation of type plate fields

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16 B 1000 en-5018
3 Assembly instructions, storage, preparation, installation
Please note all safety information (please see chapter 1 "Safety information")and warning information
in the relevant sections.
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3.1 Transporting the gear unit
WARNING
Hazard due to falling loads
• The thread of the eyebolt must be fully screwed in.
• Do not pull on the eyebolt at an angle.
Only use the eyebolts attached to the gear unit for transport. If geared motors have an additional
eyebolt attached to the motor, this must also be used.
Transport the gear unit with care. Impacts to the free ends of the shafts may cause internal damage to
the gear unit.
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3.2 Storage
For short-term storage before commissioning, please observe the following:
• Store gear units in the fitting position ((please see chapter 7.1 "Versions and maintenance")) and
secure them against falling,
• Lightly oil bare metal housing surfaces and shafts
• Store in a dry place,
• Temperature in the range from – 5 °C to + 50 °C without large fluctuations,
• Relative humidity less than 60 %,
• No direct exposure to sunlight or UV light,
• No aggressive, corrosive substances (contaminated air, ozone, gases, solvents, acids, alkalis,
salts, radioactivity etc.) in the immediate vicinity,
• No vibration or oscillation
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3.3 Long-term storage

For storage or standstill periods in excess of 9 months, Getriebebau NORD recommends the long-
term storage option. With the use of the measures listed below, storage for up to 2 years is possible.
As the actual influences on the unit greatly depend on the local conditions, these times should only be
regarded as guide values.
Conditions of the gear unit and storage area for long-term storage prior to commissioning:
• Store in the fitting position (please see chapter 7.1 "Versions and maintenance")and secure them
against falling.
• Transportation damage to the external paint must be repaired. Check that a suitable rust inhibitor is
applied to the flange bearing surfaces. If necessary apply a suitable rust inhibitor to the surfaces.
• Gear units with the long-term storage option are completely filled with lubricant or have VCI
corrosion protection agent mixed with the gear oil (see adhesive label on the gear unit, or are not
filled with oil, but rather with small quantities of VCI concentrate.
• The sealing band in the vent plug must not be removed during storage. The gear unit must remain
sealed tight.
B 1000 en-5018 17
• Store in a dry place.
• In tropical regions the drive unit must be protected against damage by insects.
• Temperature in the range from – 5 °C to + 40 °C without large fluctuations.
• Relative humidity less than 60 %.
• No direct exposure to sunlight or UV light.
• No aggressive, corrosive substances (contaminated air, ozone, gases, solvents, acids, alkalis,
salts, radioactivity etc.) in the immediate vicinity.
• No vibration or oscillation
Measures during storage or standstill periods
• If the relative humidity is < 50 % the gear unit can be stored for up to 3 years.
Measures before commissioning
• Inspect the gear unit before commissioning.
• If the storage or standstill period exceeds 2 years or the temperature during short-term storage has
greatly deviated from the standard range, the lubricant in the gear unit must be replaced before
commissioning.
• If the gear unit is completely filled, the oil level must be reduced before commissioning.
• For gear units without oil filling, the oil level for the version must be filled before commissioning.
The VCI concentrate may remain in the gear unit. Lubricant quantities and types must be filled
according to the details on the type plate.
18 B 1000 en-5018
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3.4 Preparing for installation

Please examine the delivery for transport and packaging damage immediately on receipt. The drive
unit must be examined and may only be installed if no damage is apparent. In particular the radial
seals and the sealing caps must be inspected for damage. Report any damage to the carrier
immediately. Gear units with transport damage must not be commissioned.
All bare metal surfaces and shafts of the gear unit are protected against corrosion with oil, grease or
corrosion protection agents before shipping.
Thoroughly remove all oil, grease or corrosion protection agents and any dirt from the shafts and
flange surfaces before assembly.
In applications where an incorrect rotational direction may result in damage or potential risk, the
correct rotational direction of the output shaft must be established by test running the drive when
uncoupled and guaranteeing such for subsequent operation.
Gears with integrated return stops are marked with arrows on the drive/driven sides. The arrows point
in the rotation direction of the gear unit. When connecting the motor and during motor control, it must
be ensured that the gear unit can only operate in the direction of rotation. (For further explanations see
catalogue G1000 and Works Standard 0-000 40)
Ensure that no aggressive or corrosive substances which attack metal, lubricants or elastomers are
present in the area surrounding the installation site or are subsequently expected during operation.
Gear units with nsd tupH surface treatment must be electrically decoupled by the use of non-
conductive intermediate layers. In case of doubt, please contact Getriebebau NORD and take the
recommended action.
Oil expansion tanks (Option OA) must be fitted in accordance with Works Standard 0-530 04. For gear
units with an M10x1 vent plug, Works Standard 0-521 35 must be also be observed during installation.
Oil level tanks (Option OT) must be fitted in accordance with Works Standard 0-521 30.
If venting of the gear unit is provided, the vent or the pressure vent must be activated before
commissioning. To activate, remove the transport securing device (sealing cord). Position of the vent
screw 7.1 "Versions and maintenance".
B 1000 en-5018 19
Explanation
1 Standard vent plug

2 Transport securing device
Figure 2: Activating the vent plug
Explanation
1 Vent screw
2 Transport securing device
Figure 3: Activating the vent plug
Special pressure vents are supplied as loose parts. Before commissioning, the vent screws must be
replaced with the special pressure vents which are supplied as loose parts. This is done by
unscrewing the vent fitting and replacing it with the special pressure vent and seal (refer to Section 7.1
"Versions and maintenance"). Double gear units consist of two single units and are equipped with 2 oil
chambers and possibly 2 pressure vents.
Explanation
1 Standard vent plug 2 Transport securing device 3 Special vent screw
Figure 4: Removing the vent plug and fitting the special pressure vent
20 B 1000 en-5018
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3.5 Installing the gear unit
NOTICE!
Damage to the gear unit due to overheating
• For geared motors, check that the cooling air from the motor fan can circulate around the gear unit
without obstruction.
The eyebolts screwed into the gear units must be used during installation. No additional load may be
attached to the gear unit.
If geared motors have an additional eyebolt attached to the motor, this must also be used. Avoid
pulling the eyebolts at an angle. Observe the safety information (please see chapter 1 "Safety
information").
The base and/or flange to which the gear unit is fitted should be vibration-free, torsionally rigid and flat.
The smoothness of the mating surface on the base or flange must be according to tolerance class K
according to DIN ISO 2768-2. All contamination to the bolting surfaces of gear unit and base and/or
flange must be thoroughly removed.
The gear housing must always be earthed. With geared motors, earthing via the motor connection
must be ensured.
The gear unit must be precisely aligned with the drive shaft of the machine in order to prevent
additional forces from being imposed on the gear unit due to distortion.
Welding of the gear unit is prohibited. The gear unit must not be used as the earth connection for
welding work, as this may cause damage to the bearings and gear wheels.
The gear unit must be installed in the correct orientation (please see chapter 7.1 "Versions and
maintenance"). (UNIVERSAL SI and SM gear unit types do not depend on the configuration).
Changes to the installation position after delivery require adjustment of the quantity of oil, and often
other measures such as e.g. the installation of encapsulated roller bearings. Damage may result if
the stated installation position is not observed.
All gear unit feet and/or all flange bolts on each side must be used. Bolts must have a minimum quality
of 8.8. The bolts must be tightened to the correct torques (please see chapter 7.4 "Torque values").
Tension-free bolting must be ensured, particularly for gear units with a foot and flange.
The oil inspection screws, oil drain screws and the vent valves must be accessible.
B 1000 en-5018 21
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3.6 Fitting hubs on the gear shafts
NOTICE!
The gear unit may be damaged by axial forces.
• Do not allow any harmful axial forces to act on the gear unit. Do not strike the hub with a hammer.
Drive and driven elements, e.g. coupling and chain-wheel hubs must be mounted onto the drive and
driven shaft of the gear unit using suitable pullers that will not apply damaging axial forces to the gear
unit.
Information
Use the end thread of the shafts for pulling. Fitting can be aided by coating the hub with lubricant or
heating it up to approx. 100 °C beforehand.
Figure 5: Example of a simple pulling device
Drive and driven elements may only subject the drive unit to the maximum radial forces FR and
axial forces FA which are specified in the catalogue. Observe the correct tension, particularly on
belts and chains.
Additional loads due to unbalanced hubs are not permitted.
The transverse force must be applied to the gear unit as closely as possible.
Figure 6: Correct assembly of drive elements

22 B 1000 en-5018
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3.7 Fitting push-on gear units
WARNING
When the screw fastenings of the torque arm are removed, the gear unit will rotate around the
output shaft
• Secure the screw fastening against loosening, e.g. with Loctite 242 or a second nut.
NOTICE!
The gear unit may be damaged by axial forces.
The bearings, gear wheels, shafts and housing may be damaged by incorrect fitting.
• Use suitable pulling devices.
• Do not strike the gear unit with a hammer.
Assembly and subsequent dismantling is aided by applying an anti-corrosive lubricant to the shaft
before fitting (e.g. NORD Anti-Corrosion Part No. 089 00099). Excess grease or anti-corrosion agent
may escape after assembly and may drip off. Clean these points on the output shaft after a running-in
time of approx. 24 hours. This escape of grease is not due to a leak in the gear unit.
Figure 7: Applying lubricant to the shaft and the hub
Information
The gear unit can be fitted to shafts with and without a shoulder using the fastening element
(Option B). Tighten the bolt of the fastening element to the correct torque (please see chapter 7.4
"Torque values"). For gear units with option H66, the factory-fitted closing cap must be removed
before assembly.
For push-on gear units with option H66 and fastening element (Option B) the pressed-in closing cap
must be pushed out before fitting the gear unit. The pressed-in closing cap may be destroyed during
dismantling. As standard a second closing cap is supplied as a loose spare part. After fitting the gear
unit, fit the new closing cap as described in Section (please see chapter 3.9 "Fitting the covers").
B 1000 en-5018 23
Figure 8: Removing the factory-fitted closing cap
Figure 9: Gear unit mounted to shaft with a shoulder using the fastening element
Figure 10: Gear unit mounted to shaft without a shoulder using the fastening element
A gear unit can be dismantled from a shaft with a shoulder using the following device, for example.
Figure 11: Dismantling using dismantling device
When assembling push-on gears with torque supports, the support must not be distorted. Tension-free
mounting is aided by the rubber buffer (Option G or VG).
24 B 1000 en-5018
Figure 12: Mounting the rubber buffer (Option G or VG) on parallel shaft gear units
To fit the rubber buffer, tighten the screw fastening until there is no play between the contact surfaces
when there is no load.
Then turn the fastening nut half a turn in order to pre-tension the rubber buffer (only applies for screw
fastenings with adjusting threads). Greater pre-tension is not permissible.
Explanation
1 Always support torque support on
both sides
Figure 13: Attaching the torque support on bevel gear and worm gear units
Tighten the fastenings of the torque support with the correct tightening torques (please see chapter
7.4 "Torque values")and secure against loosening (e.g. Loctite 242, Loxeal 54-03).
B 1000 en-5018 25
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3.8 Fitting shrink discs
NOTICE!
Damage to the hollow shaft
• Do not tighten the clamping bolts if the solid shaft is not inserted.
Explanation
1 Shrink disc, type, part no. and torque details
for tensioning screws
2 Tensioning flanges
3 Solid shaft of machine
4 Shaft and hollow shaft bore FREE OF
GREASE
5 Hollow shaft of gear unit
6 Double half-slotted inner ring
7 Tensioning screws DIN 931 (933) -10.9
Figure 14: Hollow shaft with shrink disc
The shrink discs are supplied by the manufacturer ready for fitting. They must not be dismantled prior
to fitting.
The solid shaft of the machine runs free of grease in the hollow shaft of the gear unit.
Assembly sequence
1. Remove any transport securing devices.
2. Loosen but do not remove tightening bolt and tighten gently by hand until there is no play between
the flanges and the inner ring.
3. Slide the shrink disc onto the hollow shaft until the outer clamping flange is flush with the hollow
shaft. The shrink disc is easier to slide on if the bore of the inner ring is lightly greased.
4. Prior to mounting, grease the solid shaft only in the area which will later come into contact with the
bronze bush in the hollow shaft of the gear unit. Do not grease the bronze bush, in order to prevent
grease penetrating the area around the shrink connection.
5. The hollow shaft of the gear unit must be completely de-greased and completely free of grease.
6. In the area of the shrink connection the solid shaft of the machine must be degreased and
completely free of grease.
7. Insert the solid shaft of the machine into the hollow shaft so as to completely fill the area around
the shrink connection.
8. Position the clamping flange by gently tightening the bolts.
9. Tighten the tensioning bolts successively in a clockwise direction by several turns – not crosswise
– with approx. ¼ rotation per turn. Tighten the bolts with a torque wrench to the torque indicated on
the shrink disc.
10. When the tensioning bolts have been tightened, there must be an even gap between the clamping
flanges. If this is not the case, the gear unit must be dismantled and the shrink disc connection
checked for correct fit.
26 B 1000 en-5018
Dismantling sequence:
1. Loosen the tensioning bolts successively in a clockwise direction by several turns with approx. ¼
rotation per turn. Do not remove the bolts from their thread.
2. Loosen the clamping flanges from the cone of the inner ring.
3. Remove the gear unit from the solid shaft of the machine.
If a shrink disk has been in use for a long period or is dirty, it must be dismantled, cleaned and the
conical surfaces coated with Molykote G Rapid Plus or a similar lubricant before it is refitted. The
threads and head surfaces of the screws must be treated with grease without Molykote. Any damaged
or corroded elements must be replaced.
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3.9 Fitting the covers

All fixing screws must be used and tightened to the correct torque (please see chapter 7.4 "Torque
values"). For covers with Option H66, press in the new / new condition closing cap by tapping it lightly
with a hammer.
Figure 15: Fitting the covers, Option SH, Option H, and Option H66
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3.10 Fitting the covers

Many versions of the universal worm gear unit are supplied with plastic cover caps as standard. These
cover caps protect the shaft sealing ring against the entry of dust and other possible contamination.
The cover caps can be removed by hand without the use of tools and pushed onto the A or B side.
The cover cap must be removed before installing the universal worm gear unit. After installation is
complete, the cover cap must be pushed into the threaded holes on the output flange on the
corresponding side. Care must be taken that the cover cap is removed and pushed on vertically, in
order not to damage the expansion elements of the cover cap.
Figure 16: Removal and fitting of the cover cap

B 1000 en-5018 27
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3.11 Fitting a standard motor

The maximum permitted motor weights indicated in the table below must not be exceeded when
attaching the motor to an IEC/NEMA adapter:
Maximum permitted motor weights

IEC motor size 63 71 80 90 100 112 132 160 180 200 225 250 280 315
NEMA motor size
/400TC
140TC
180TC
210TC
250TC
280TC
320TC
360TC
56C
Max. motor weight [kg] 25 30 40 50 60 80 100 200 250 350 500 700 1000 1500
Assembly procedure to attach a standard motor to the IEC adapter (Option IEC/NEMA adapter)
1. Clean the motor shaft and flange surfaces of the motor and the IEC /NEMA adapter and check for
damage. The mounting dimensions and tolerances of the motor must conform to
DIN EN 50347 / NEMA MG1 Part 4.
2. Push the coupling sleeve onto the motor shaft so that the motor parallel key engages into the
groove in the sleeve on tightening.
3. Tighten the coupling sleeve on the motor shaft in accordance with the motor manufacturer’s
instructions until it touches the collar. With motor sizes 90, 160, 180 and 225, any spacer bushes
must be positioned between the coupling sleeve and the collar. With standard helical gear units,
dimension B between the coupling sleeve and the collar must be observed (see Figure 17). Certain
NEMA adapters require adjustment of the coupling in accordance with the specifications indicated
on the adhesive plate.
4. If the coupling half contains a threaded pin, the coupling must be secured axially on the shaft. The
threaded pin must be coated prior to use with a securing lubricant e. g. Loctite 242, Loxeal 54-03
and tightened to the correct torque (please see chapter 7.4 "Torque values").
5. Sealing of the flange surfaces of the motor and the IEC/NEMA adapter is recommended if the
motor is installed outdoors or in a humid environment. Before the motor is installed, the flange
surfaces must be completely coated with surface sealant Loctite 574 or Loxeal 58-14 so that the
flange seals after mounting.
6. Mount the motor on the IEC/NEMA adapter. Do not forget to fit the gear rim or the splined sleeve
provided (see illustration below).
7. Tighten the bolts of the IEC/NEMA adapter with the correct torque (please see chapter 7.4 "Torque
values").
28 B 1000 en-5018
Figure 17: Fitting the coupling onto the motor shaft - various types of coupling
I Curved tooth coupling

II Curved tooth coupling, two-part
III Curved tooth coupling, two-part with spacer bush
IV Claw coupling, two-part
V Claw coupling, two-part, observe dimension B:
Standard helical gear unit:
IEC size 63 IEC size 71
Dimension B (Fig. V) B = 4.5 mm B = 11.5 mm
VI Claw coupling two-part with spacer bush
B 1000 en-5018 29
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3.12 Fitting the cooling coil to the cooling system

The cooling coil is installed in the housing cover. Cutting ring screw threads according to DIN 2353 are
located at the casing cover for the connection of a pipe with an external diameter of 10 mm.
Remove the closing cap from the screw neck prior to assembly to avoid any contamination of
the cooling system. The screw necks should be connected with the coolant circuit, which must be
provided by the operator. The flow direction of the coolant is irrelevant.
Make sure not to twist the screw necks during or after assembly as the cooling coil may be
damaged. It must be ensured that no external forces act on the cooling coil.
Explanation
1 Cutting ring screw threads

2 Cooling coil
3 Housing cover
Figure 18: Cooling cover

30 B 1000 en-5018
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3.13 External oil-air cooler
NOTICE!
The gear unit is supplied without the oil filling.
• Fill the gear unit with oil before commissioning.
The oil-air cooler is delivered as an additional unit. The scope of delivery includes the oil-air cooler and
the necessary connection hoses. Installation of the hoses and commissioning are performed by the
plant operator.
3.13.1 Assembling the cooling system

Connect the cooling system as shown in the illustration.
1 Oil-air cooler
2 Gear unit
3 Optional temperature monitoring
S Intake connection / gear unit oil drain
Gear unit pressure connection above or
P
below the oil level
Figure 19: Connecting the cooling system
Fit the union nuts according to(please see chapter 7.4 "Torque values").
After assembling the oil lines, fill the gear unit housing with the gear oil type and quantity that is printed
on the type plate. Approximately 4.5 l of oil are additionally required for the hose lines. When filling,
always use the oil level screw as an indicator of the precise quantity of oil. The oil quantity on the type
plate is a guide value and may vary, depending on the gear ratio.
3.13.2 Oil-air cooler electrical connection

Please comply with all national safety regulations for the electrical connection. Please observe all
applicable documents, in particular the operating and installation instructions for the oil-air cooler.
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3.14 Installation of an oil expansion tank, Option OA

The expansion tank must be installed vertically with the hose connection facing downwards and the
vent plug upwards. If the tank is not fitted, observe the following steps for fitting:
B 1000 en-5018 31
• After installing the gear unit (motor), remove the vent screw on the gear unit.
• For modules 0.7 l, 2.7 l and 5.4 l the reduction / extension is screwed in with the
existing sealing ring.
• Now fit the expansion tank (see below for suggested position).
Note: If the necessary screw insertion depth of 1.5d can no longer be achieved, use a
5 mm longer screw. If a longer screw cannot be fitted, use a stud and a nut with
appropriate dimensions.
If the fastening screw is screwed into a through hole, seal the thread with a medium
strength screw securing material such as LOXEAL 54-03 or Loctite 242.
• The tank should be fitted as high as possible. - Note the length of the hoses!! -
• After this, fit the vent hose with the enclosed hollow screws and seals.
Finally, screw the enclosed M12x1.5 vent screw and sealing ring into the tank.
Notice: For ATEX gear units, screw the enclosed M12x1.5 vent screw into the tank.
Figure 20: Installing the expansion tank
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3.15 Subsequent paintwork

For retrospective painting of the gear unit, the radial seals, rubber elements, pressure venting valves,
hoses, type plates, adhesive labels and motor coupling components must not come into contact with
paints, lacquers or solvents, as otherwise components may be damaged or made illegible.
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32 B 1000 en-5018
4 Commissioning
4 Commissioning
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4.1 Check the oil level

The oil level must be checked prior to commissioning (please see chapter 5.2 "Service and
Maintenance Work").
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4.2 Activating the automatic lubricant dispenser

Some gear unit types with standard motor (Option IEC/NEMA) have an automatic lubricant dispenser
for the roller bearings. This dispenser must be activated prior to commissioning. The cartridge case
cover of the adapter for attaching an IEC/NEMA standard motor has a red information sign for the
activation of the lubricant dispenser. A grease escape opening which is closed with a G1/4 cap screw
is located opposite to the lubricant dispenser. After activation of the lubricant dispenser, the cap screw
can be removed and replaced with the grease collection container (Part No. 28301210) which is
supplied separately with the delivery.
Activating the automatic lubricant dispenser:
1. Loosen and remove the cylindrical screws.
2. Remove the cartridge cover.
3. Screw the activation screw into the lubricant dispenser until the lug breaks off at the defined
fracture point
4. Re-fit the cartridge cover and fasten it with the cylindrical screw (please see chapter 7.4 "Torque
values").
5. Mark activation date on the adhesive label indicating the month/year
Explanation
1 Cylindrical screw M8 x 16
2 Cartridge cover
3 Activation screw
4 Lug
5 Lubricant sensor
6 Position of adhesive label
Figure 21: Activating the automatic lubricant dispenser with standard motor mounting
B 1000 en-5018 33
Adhesive label:
Notice!
Screw in the activation screw until the lug breaks off before
commissioning the gear unit.
Dispensing time: 12 Months
Month Activation date Year
1 2 3 4 5 6 7 8 9 10 11 12 06 07 08 09 10
11 12 13 14 15
Figure 22: Adhesive label

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4.3 Operation with lubricant cooling

Water cooling
The coolant must have a similar thermal capacity as water (specific thermal capacity at 20 °C
c=4.18 kJ/kgK). Industrial water without any air bubbles or sediments is recommended as a coolant.
The hardness of the water must be between 1 dH and 15 dH; the pH value must be between pH 7.4
and pH 9.5. No aggressive liquids may be added to the coolant!
The coolant pressure must not exceed 8 bar. The required quantity of coolant is 10 litres/minute,
and the coolant inlet temperature must not exceed 40 °C; we recommend 10 °C.
We also recommend fitting a pressure reducer or similar at the coolant inlet to avoid damage due to
excessive pressure.
If there is a danger of frost the operator should add a suitable anti-freeze solution to the cooling water.
The temperature of the cooling water and the cooling water flow rate must be supervised and
ensured by the operator.
Air/Oil cooler
The version and all important data for the air/oil cooler can be obtained from Catalogue G1000, or
contact the manufacturer of the cooling unit.
34 B 1000 en-5018
4 Commissioning
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4.4 Running-in time for the worm gear unit

In order to achieve maximum efficiency of the worm gear unit, the gear unit must be subjected to a
running-in period of approx. 25 h – 48 h under maximum load.
There may be a reduction in efficiency before the running-in period is complete.
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4.5 Checklist
Checklist
Subject of check Date Information

checked: see Section
Is the vent plug activated or the pressure vent screwed in? 3.4
Does the required configuration conform with the actual 7.1
installation?
Are the external gear shaft forces within permitted limits (chain 3.6
tension)?
Is the torque support correctly fitted? 3.7
Are contact guards fitted to rotating components? 3.9
Is the automatic lubricant dispenser activated? 4.2
Is the cooling cover connected to the cooling circuit? 3.12
3.13
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B 1000 en-5018 35
5 Service and maintenance

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5.1 Service and Maintenance Intervals
Service and Maintenance

Intervals Service and Maintenance Work Information
see Section
At least every six months • Visual inspection 5.2
• Check for running noises
• Check the oil level
• Visual inspection of hose
• Re-grease / remove excess grease
(only applicable for free drive shaft / Option W and for agitator
bearings / Option VL2 / VL3)
• Replace the automatic lubricator /
remove excess grease
(for operating times < 8 h/day: A replacement interval of
1 year is permissible for the lubricant dispenser) (Only for
IEC / NEMA standard motor mounting). Empty or replace the
lubricant collection container with every second replacement
of the lubricant dispenser.
For operating temperatures • Change the oil (the interval is doubled if filled with synthetic 5.2
up to 80 °C, products)
every 10000 operating • Cleaning or replacing the vent plug
hours, • Replace the shaft sealing rings
at least every 2 years
Every 20000 operating • Re-lubrication of the bearings in the gear unit 5.2
hours,
at least every 4 years
At least every 10 years • General overhaul 5.2
Information
The oil change intervals apply for normal operating conditions and operating temperatures up to
80 °C. The oil change intervals are reduced in the case of extreme conditions (operating temperatures
higher than 80 °C, high humidity, aggressive environment and frequent fluctuations in the operating
temperature).
36 B 1000 en-5018
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5.2 Service and Maintenance Work

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Visual inspection
The gear unit must be checked for leaks. In addition, the gear unit must be inspected for external
damage and cracks in the hoses, hose connections and rubber buffers. Have the gear unit repaired in
case of leaks, e.g. dripping gear oil or cooling water, damage or cracks. Please contact the NORD
service department.
Information
Shaft sealing rings are components with a limited life and are subject to wear and ageing. The service
life of shaft sealing rings depends on various ambient conditions. Temperature, light (especially UV
light), ozone and other gases and liquids affect the ageing process of shaft sealing rings. Some of
these influences may change the physical or chemical properties of the shaft sealing rings and result
in a significant reduction of their service life. Foreign substances (e.g. dust, sludge, sand, metallic
particles) and excess temperature (excessive speed or external heating) accelerate the wear of the
sealing lip. These sealing lips are made of an elastomer material and are lubricated with a special
grease at the factory. This reduces the wear due to their function and ensures a long service life. An
oil film in the region of the rubbing sealing lip is therefore normal and is not due to leakage (please
see chapter 7.6 "Leakage and leak-tightness").
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Check for running noises

If the gear unit produces unusual running noises and/or vibrations, this could indicate damage to the
gear unit. In this case the gear should be shut down and a general overhaul carried out.
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Check the oil level

Section 7.1 "Versions and maintenance"describes the mounting positions and the corresponding oil
level screws. With double gear units, the oil level must be checked on both units. The pressure vent
must be at the position marked in Section 7.1 "Versions and maintenance".
The oil level does not need to be checked on gear units without oil level screw (please see chapter 7.1
"Versions and maintenance").
Gear unit types that are not supplied full of oil must be filled before the oil level is checked.
Check the oil level with an oil temperature of between 20 °C to 40 °C.
1. The oil level may only be checked when the gear unit is at a standstill and has cooled down. The
gear unit must be secured to prevent accidental activation.
2. The oil level screw corresponding to the actual mounting position must be screwed out(please see
chapter 7.1 "Versions and maintenance").
Information
At the first oil level check a small amount of oil may escape, as the oil level may be above the lower
edge of the oil level hole.
3. Gear units with oil level screw: The correct oil level is at the bottom edge of the oil level hole. If
the oil level is too low, this must be corrected with the appropriate type of oil. Optionally, an oil level
glass is also possible instead of the oil level screw.
4. Gear units with oil tank: Der The oil level must be checked with the aid of the cap screw with
dipstick (G1¼ thread) in the oil tank. The oil level must be between the top and bottom marking
when the dipstick is fully screwed in (see Figure 23). Top up the oil level with the relevant type of oil
B 1000 en-5018 37
as necessary. These gearboxes may only be operated in the mounting position stated in
Section 7.1 "Versions and maintenance".
5. The oil level screw or the cap screw with dipstick and all other loosened screws must be correctly
re-tightened.
Figure 23: Checking the oil level with a dipstick

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Visual inspection of hose

Gear units with an oil tank (Option OT) and external cooling units have rubber hoses. After assembling
the oil lines, fill the gear unit housing with the gear oil type and quantity that is printed on the type
plate. Please contact the NORD service department.
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Re-greasing
Some gear unit designs (free drive shaft, Option W, agitator designs VL2 and VL3) are equipped with
a re-greasing device.
For agitator versions VL2 and VL3, the vent screw located opposite to the grease nipple must be
unscrewed before re-greasing. Grease should be injected until a quantity of 20 - 25 g escapes from
the vent hole. After this, the vent plug must be reinserted and tightened.
For Option W and some IEC adapters, the outer roller bearing must be re-greased with approx.
20 - 25 g of grease via the grease nipple provided. Remove any excess grease from the adapter.
Recommended grease: Petamo GHY 133N (please see chapter 7.2 "Lubricants")(Klüber Lubrication),
a food compatible grease is possible as an option.
38 B 1000 en-5018
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Replacing the automatic lubricant dispenser
Explanation
1 Cylindrical screws M8 x 16
2 Cartridge cover
3 Activation screw
4 Lug
5 Lubricant sensor
6 Position of adhesive label
Figure 24: Replacing the automatic lubricant dispenser with standard motor mounting
The cartridge cover must be unscrewed. The lubrication dispenser is screwed out and replaced with a
new component (Part No. 28301000 or for food-compatible grease Part No.: 28301010). Remove any
excess grease from the adapter. Then activate (please see chapter 4.2 "Activating the automatic
lubricant dispenser").
Empty or replace the grease collection container (Part No. 28301210) with every second replacement
of the lubricant container. To empty the container, unscrew it from the screw fitting. The container has
an internal piston, which can be pressed back with a rod with a maximum diameter of 10 mm. Collect
the grease which is pressed out and dispose of it correctly. Due to the shape of the container, a
residual quantity of grease remains in the container. After emptying and cleaning the container, it can
be screwed back into the drain hole in the IEC adapter. Replace the container with a new one if it is
damaged.
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Change the oil

The figures in Section 7.1 "Versions and maintenance"show the oil drain screw, the oil level screw and
the pressure vent screw for various designs.
Procedure:
1. Place a catchment vessel under the oil drain screw or the oil drain tap.
2. Completely remove the oil level screw or screwed sealing plug with dipstick if an oil level tank is
being used and unscrew oil drain screw.
3. Drain all the oil from the gear unit.
4. If the sealing ring of the oil drain screw or oil level screw is damaged in the thread, a new oil level
screw must be used or the thread must be cleaned and coated with securing lubricant, e.g.
Loctite 242, Loxeal 54-03 prior to insertion.
5. Screw the oil drain screw into the hole and tighten to the correct torque (please see chapter 7.4
"Torque values").
6. Using a suitable filling device, refill with oil of the same type through the oil level hole until oil
emerges from the oil level hole. (The oil can also be filled through the pressure vent screw or a
sealing plug located higher than the oil level). If an oil level tank is used, fill the oil through the
upper inlet (thread G1¼) until the oil level is set as described in Section 5.2 "Service and
Maintenance Work".
7. Wait at least 15 minutes, or at least 30 minutes if an oil level tank is used, and then check the oil
level. Proceed as described in Section 5.2 "Service and Maintenance Work".
B 1000 en-5018 39
Information
The oil does not need to be changed on gear units without oil level screw (please see chapter 7.1
"Versions and maintenance"). These gear units are lubricated for life.
Standard helical gear units have no oil level screw. Here, the oil is topped up through the pressure
vent bolt using the quantities listed in the table in Section "Helical gear units".
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Cleaning or replacing the vent plug

Unscrew the vent screw and thoroughly clean it (e.g. with compressed air) and fit the vent screw in the
same place, If necessary, use a new vent screw with a new sealing ring.
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Replace the shaft sealing ring

Once the shaft sealing ring has reached the end of its service life, the oil film in the region of the
sealing lip increases and a measurable leakage with dripping oil occurs. The shaft sealing ring must
then be replaced. The space between the sealing lip and the protective lip must be filled
approximately 50 % with grease on fitting (recommended grease: PETAMO GHY 133N). Take care
that after fitting, the new shaft sealing ring does not run in the old wear track.
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Re-lubricating bearings
For bearings which are not oil-lubricated and whose holes are completely above the oil level, replace
the roller bearing grease (recommended grease: PETAMO GHY 133N). Please contact the NORD
service department.
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General overhaul
For this, the gear unit must be completely dismantled. The following work must be carried out:
– clean all gear unit components,
– examine all gear unit components for damage,
– all damaged components must be replaced,
– all roller bearings must be replaced,
– replace back stops if fitted,
– replace all seals, radial seals and Nilos rings,
– replace plastic and elastomer components of the motor coupling.
The general overhaul must be carried out by qualified personnel in a specialist workshop with
appropriate equipment in observance of national regulations and laws. We recommend that the
general overhaul is carried out by the NORD Service department.
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40 B 1000 en-5018
6 Disposal
6 Disposal
Observe the current local regulations. In particular, lubricants must be collected and disposed of
correctly.
Gear unit components Material
Gear wheels, shafts, rolling bearings, parallel keys,locking rings, … Steel
Gear unit housing, housing components, … Grey cast iron
Light alloy gear unit housing, light alloy gear unit housing components, … Aluminium
Worm gears, bushes, ... Bronze
Radial seals, sealing caps, rubber components,… Elastomers with steel
Coupling components Plastic with steel
Flat seals Asbestos-free sealing material
Gear oil Additive mineral oil
Synthetic gear oil (adhesive label: CLP PG) Polyglycol-based lubricants
Cooling spiral, embedding material of the cooling spiral, screw fittings Copper, epoxy, yellow brass
Table 3: Disposal of materials

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B 1000 en-5018 41
7 Appendix
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7.1 Versions and maintenance

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Explanation of symbols for the following mounting position illustrations:
Venting
Oil level
Oil drain
Information
SK 320, SK 172, SK 272, SK 372 as well as SK 273 and SK 373, SK 01282 NB, SK 0282 NB,
SK 1382 NB and UNIVERSAL / MINIBLOC gear units are lubricated for life. These gear units do not
have an oil filler screw.
UNIVERSAL / MINIBLOC worm gear units

NORD UNIVERSAL / MINIBLOC worm gear units are suitable for all installation positions. They have
an oil filling which is independent of the mounting position.
As an option, types SI and SMI can be equipped with a vent screw. Gear units with vents must be
installed in the stated mounting position.
Types SI, SMI, S, SM and SU as 2-stage gear unit types and types SI, SMI as worm gear units for
direct motor mounting have an oil filling which depends on the mounting position and must be installed
in the stated position.
42 B 1000 en-5018
7 Appendix
Parallel shaft gear units with oil level tank

The following applies for parallel shaft gear units SK 9282, SK 9382, SK 10282, SK 10382,
SK 10382.1, SK 11282, SK 11382, SK 11382.1 and SK 12382 in installation position M4 with oil tank:
Figure 25: Oil level check with oil level tank

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B 1000 en-5018 43
44 B 1000 en-5018
7 Appendix
B 1000 en-5018 45
46 B 1000 en-5018
7 Appendix
B 1000 en-5018 47
48 B 1000 en-5018
7 Appendix
B 1000 en-5018 49
50 B 1000 en-5018
7 Appendix
B 1000 en-5018 51
52 B 1000 en-5018
7 Appendix
B 1000 en-5018 53
54 B 1000 en-5018
7 Appendix
B 1000 en-5018 55
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56 B 1000 en-5018
7 Appendix
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7.2 Lubricants
With the exception of type SK 11282, SK 11382, SK 12382 and SK 9096.1 gear units, all gear units
are filled with lubricant ready for operation in the required installation position when delivered. This
initial filling corresponds to a lubricant from the column for the ambient temperatures (normal version)
in the lubricant table.
Roller bearing greases
This table shows comparable roller bearing greases from various manufacturers. The manufacturer
can be changed for a given grease type. Getriebebau NORD must be contacted in case of change of
grease type or ambient temperature range, as otherwise no warranty for the functionality of our gear
units can be accepted.
Lubricant type Ambient

temperature
Mineral Renolit
oil-based grease Tribol GR 100-2 PD GP 2 Gadus S2
-30 … 60 C - Mobilux EP 2
Renolit V100 2
LZR 2 H
Renolit WTF
-50 … 40 C Optitemp LG 2 - - -
2
Synthetic grease Renolit PETAMO
Tribol GR 4747/220-
HLT 2 GHY 133 N Mobiltemp
-25 … 80 °C 2 HAT
Renolit Klüberplex SHC 32
LST 2 BEM 41-132
Biodegradable Plantogel Klüberbio Mobil SHC Grease
-25 … 40 °C - Naturelle Grease EP2
grease 2S M 72-82 102 EAL
Table 4: Roller bearing greases
B 1000 en-5018 57
Lubricant table
This table shows comparable lubricants from various manufacturers. The manufacturer can be
changed within a particular viscosity or lubricant type. Getriebebau NORD must be contacted in case
of change of viscosity or lubricant type, as otherwise no warranty for the functionality of our gearboxes
can be accepted.
Lubricant Details on DIN (ISO) /
type type plate Ambient
temperature
Alpha EP 680 Carter EP 680

Alpha SP 680 Renolin CLP 680 Carter XEP 680
ISO VG 680 Klüberoil Mobilgear Omala
CLP 680 Optigear BM 680 Renolin CLP 680
0...40 °C GEM 1-680 N 600 XP 680 S2 G 680
Optigear Synthetic Plus
1100/680
Renolin CLP 220
Alpha SP 220 Carter XEP 220
Mineral oil
ISO VG 220 Renolin CLP 220

Optigear BM 220 Klüberoil Mobilgear Omala
CLP 220 -10…40 °C Plus
Optigear Synthetic GEM 1-220 N 600 XP 220 S2 G 220
Renolin Gear 220
1100/220
VCI

Alpha SP 100 Renolin CLP 100
ISO VG 100 Klüberoil Mobilgear Omala
CLP 100 Optigear BM 100 Renolin CLP 100
-15…25 °C GEM 1-100 N 600 XP 100 S2 G 100
Optigear Synthetic Plus
1100/100
ISO VG 680 Alphasyn GS 680 Carter SY 680
CLP PG Renolin Klübersynth Mobil Omala
-20...40 °C Optigear Synthetic Carter SG 680
680 PG 680 GH 6-680 Glygoyle 680 S4 WE 680
Synthetic oil
(Polyglycol)
800/680
Alphasyn GS 220 -
ISO VG 220
CLP PG Alphasyn PG 220 Renolin Klübersynth Mobil Omala
-25…80 °C
220 Optigear Synthetic PG 220 GH 6-220 Glygoyle 220 S4 WE 220
800/220
Alphasyn EP 460 Carter SH 460
CLP HC ISO VG 460 Renolin Unisyn Klübersynth Mobil Omala
  (hydrocarbon)
460 -30…80 °C Optigear Synthetic CLP 460 GEM 4-460 N SHC 634 S4 GX 460
Synthetic oil
PD 460
Alphasyn EP 220 Renolin Unisyn Carter SH 220
CLP HC ISO VG 220 CLP 220 Klübersynth Mobil Omala
220 -40…80 °C Optigear Synthetic Renolin Unisyn GEM 4-220 N SHC 630 S4 GX 220
PD 220 Gear VCI
ISO VG 680 -
CLP E 680 - Plantogear 680 S - - -
-5…40 °C
Bio-degradable
Performance Bio -
Naturelle
GE 220 ESS
oil
ISO VG 220 Klübersynth Gear

CLP E 220 Performance Bio Plantogear 220 S -
-5…40 °C GEM 2-220 Fluid
GE 220 ESU
EP 220
58 B 1000 en-5018
7 Appendix
Lubricant Details on DIN (ISO) /

type type plate Ambient
temperature
Optileb GT -
CLP PG ISO VG 680 Klübersynth Mobil
1800/680 Cassida Fluid WG
H1 680 -5…40 °C UH1 6-680 Glygoyle 680
680
Nevastane SY
Food grade oil
CLP PG ISO VG 220 Optileb GT Klübersynth Mobil 220

Cassida Fluid WG
H1 220 -25…40 °C 1800/200 UH1 6-220 Glygoyle 220
220
CLP HC ISO VG 680 Cassida Fluid GL Klüberoil -

Optileb GT 680 -
H1 680 -5…40 °C 680 4 UH1-680 N
Mobil Nevastane
CLP PG ISO VG 220 Cassida Fluid GL Klüberoil
Optileb GT 220 SHC Cibus XSH 220
H1 220 -25…40 °C 220 4 UH1-220 N
220
Mobil Multis EP 00
Tribol GR 100-00 Renolit Duraplex MICROLUBE Alvania
Gear unit fluid
Chassis
PD EP 00 GB 00 EP(LF)2
Grease LBZ
grease
-25 … 60 °C Tribol GR
3020/1000-00 PD Mobil Marson SY 00
Renolit Klübersynth
Spheerol EPL 00 Glygoyle -
LST 00 GE 46-1200
Grease 00
Table 5: Lubricant table

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B 1000 en-5018 59
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7.3 Lubricant quantities
Information
After changing the lubricant, and in particular after the initial filling, the oil level may change during the
first few hours of operation, as the oil galleries and the hollow spaces only fill gradually during
operation.
The oil level is still within the permissible tolerance.
If at the express request of the customer, an oil inspection glass is installed at an additional charge,
we recommend that the customer corrects the oil level after an operating period of approx. 2 hours, so
that when the gear unit is at a standstill and has cooled down, the oil level is visible in the inspection
glass. Only then, is it possible to check the oil level by means of the inspection glass.
The filling quantities stated in the following tables are for guidance only. The precise quantities vary
depending on the exact gear ratio. When filling, always observe the oil level screw hole as an
indicator of the precise quantity of oil.
Gear unit types SK 11282, SK 11382, SK 11382.1, SK 12382 and SK 9096.1 are normally supplied
without oil.
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60 B 1000 en-5018
7 Appendix
Helical gear units
Table 6: Lubricant quantities for helical gear units
B 1000 en-5018 61
NORDBLOC
Table 7: Lubricant quantities for NORDBLOC
62 B 1000 en-5018
7 Appendix
Table 8: Lubricant quantities for NORDBLOC helical gear units
B 1000 en-5018 63
Table 9: Lubricant quantities for standard helical gear units
64 B 1000 en-5018
7 Appendix
Table 10: Lubricant quantities for parallel shaft gear units
B 1000 en-5018 65
Bevel gear units
Table 11: Lubricant quantities for bevel gear units
66 B 1000 en-5018
7 Appendix
Table 12: Lubricant quantities for helical worm gear units

B 1000 en-5018 67
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7.4 Torque values
Bolt torques [Nm]
Screw connections in the Screw

strength classes Cover Threaded pin connections
Dimensions
screws on coupling on protective
8.8 10.9 12.9
covers
M4 3.2 5 6 - - -
M5 6.4 9 11 - 2 -
M6 11 16 19 - - 6.4
M8 27 39 46 11 10 11
M10 53 78 91 11 17 27
M12 92 135 155 27 40 53
M16 230 335 390 35 - 92
M20 460 660 770 - - 230
M24 790 1150 1300 80 - 460
M30 1600 2250 2650 170 - -
M36 2780 3910 4710 - - 1600
M42 4470 6290 7540 - - -
M48 6140 8640 16610 - - -
M56 9840 13850 24130 - - -
G½ - - - 75 - -
G¾ - - - 110 - -
G1 - - - 190 - -
G1¼ - - - 240 - -
G1½ 300 -
Table 13: Torque values
Assembling the hose fittings

Oil the thread of the union nut, the cutting ring and the screw neck. Tighten the union nut with the
wrench until the point where the union nut can only be turned with considerably more force. Turn the
union nut of the screw fitting approx. 30° to 60° further but not more than 90°. For this the screw neck
must be held with a wrench. Remove excess oil from the screw fitting
68 B 1000 en-5018
7 Appendix
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7.5 Troubleshooting
WARNING
Danger of slipping in case of leaks
• Clean the soiled floor before starting troubleshooting.
NOTICE!
Gear unit damage
• Shut down the gear unit immediately in case of malfunction.
Gear unit malfunctions

Fault Possible cause Remedy
Oil too low or
Unusual running noises,
bearing damage or Consult NORD Service
vibrations
gear wheel damage
Oil escaping from the gear unit
Defective seal Consult NORD Service
or motor
Incorrect oil level or
Oil change,
Oil escaping from pressure vent incorrect, contaminated oil or
use oil expansion tank (Option OA)
unfavourable operating conditions
Unfavourable installation conditions
Gear unit becomes too hot Consult NORD Service
or gear unit damage
Replace elastomer gear rim,
Defective motor coupling or
Shock when switching on, tighten motor and gear unit
loose gear unit mounting or
vibrations fastening bolts,
defective rubber element
replace rubber element
Fracture in gear unit or
Output shaft does not rotate
defective motor coupling or Consult NORD Service
although motor is running
shrink disc slippage
Table 14: Overview of malfunctions

B 1000 en-5018 69
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7.6 Leakage and leak-tightness

Gear units are filled with oil or grease to lubricate the moving parts. Seals prevent the escape of
lubricants. A complete seal is technically not possible, as a certain film of moisture, for example on the
radial shaft sealing rings is normal and advantageous for a long-term seal. In the region of vents,
moisture due to oil may be visible due to the escape of oil mist because of the function. In the case of
grease-lubricated labyrinth seals, e.g. Taconite sealing systems, used grease emerges from the
sealing gap due to the principle of operation. This apparent leak is not a fault.
According to the test conditions as per DIN 3761, the leak is determined by the medium which is to be
sealed, which in test bench tests exceeds the function-related moisture in a defined test period and
which results in dripping of the medium which is to be sealed. The measured quantity which is then
collected is designated as leakage.
Definition of leakage according to DIN 3761 and its appropriate use

Location of leak
Radial shaft
Term Explanation In IEC adapter Housing joint Venting
seal
No moisture No reason for No reason for No reason for No reason for
Sealed
apparent complaint complaint complaint complaint
Moisture film locally
No reason for No reason for No reason for No reason for
Damp restricted (not an
complaint complaint complaint complaint
area)
Moisture film beyond
No reason for No reason for Repair if No reason for
Wet the extent of the
complaint complaint necessary complaint
component
Measurable Recognisable Repair Repair Repair Repair
leakage stream, dripping recommended recommended recommended recommended
Temporary
malfunction of the
Temporary No reason for No reason for Repair if No reason for
sealing system or oil
leakage complaint complaint necessary complaint
leak due to
transport *)
Apparent leakage,
e.g. due to soiling,
Apparent No reason for No reason for No reason for No reason for
sealing systems
leakage complaint complaint complaint complaint
which can be re-
lubricated
Table 15: Definition of leaks according to DIN 3761
*) Previous experience has shown that moist or wet radial shaft sealing rings stop leaking later.
Therefore, under no circumstances can replacement be recommended at this stage. The reason for
momentary moisture may be e.g. small particles under the sealing lip.
70 B 1000 en-5018
7 Appendix
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7.7 Repair information

For enquiries to our technical and mechanical service departments, please have the precise gear unit
type (type plate) and if necessary the order number (type plate) to hand.
7.7.1 Repairs
The device must be sent to the following address if it needs repairing:
Getriebebau NORD GmbH & Co. KG

Service Department
Getriebebau-Nord-Straße 1
22941 Bargteheide
No guarantee can be given for any attachments, such as encoders or external fans, if a gear unit or
geared motor is sent for repair.
Please remove all non-original parts from the gear unit or geared motor.
Information
If possible, the reason for returning the component/device should be stated. If necessary, at least one
contact for queries should be stated.
This is important in order to keep repair times as short and efficient as possible.
7.7.2 Internet information

In addition, the country-specific operating and installation instructions in the available languages can
be found on our Internet site: www.nord.com
Pos : 111 /Anleitungen/Getri ebe/1. Hi nweise/Gewährleis tung @ 22\mod_1531824598381_388.doc x @ 2433337 @ 2 @ 1
7.8 Warranty
NORD GmbH & Co. KG accepts no liability for damage to persons, materials or assets as a result of
failure to observe this operating manual, operating errors or incorrect use. General wearing parts, e.g.
radial seals are excluded from the warranty.
B 1000 en-5018 71
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7.9 Abbreviations
2D Dust explosion protected gear units zone 21 FA Axial force
2G Explosion protected gear units with ignition IE1 Motors with standard efficiency
protection class "c"
3D Dust explosion protected gear units zone 22 IE2 Motors with high efficiency
ATEX ATmospheres EXplosibles IEC International Electrotechnical Commission
B5 Flange fastening with through holes NEMA National Electrical Manufacturers Association
B14 Flange fastening with threaded holes IP55 International Protection
CW Clockwise, right-hand direction of rotation ISO International Standardisation Organisation
CCW Counter-clockwise, left-hand direction of pH pH value
rotation
°dH Water hardness in German hardness PPE Personal Protective Equipment
degrees: 1°dH = 0.1783 mmol/l
DIN German standards institute RL Directive
EC European Community VCI Volatile Corrosion Inhibitor
EN European standard WN Getriebebau NORD factory standard
FR Radial transverse force
=== Ende der Liste für T extmar ke Inhalt ===
72 B 1000 en-5018
Key word index
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Key word index

=== Ende der Liste für T extmar ke Stichwortverzeic hnis ===
A Check the oil level ..................................... 37
Activating the vent .........................................19 Lubricant sensor ........................................ 39
Address..........................................................71 Radial shaft seal ........................................ 40
Assembly .......................................................19 Re-greasing VL2, VL3 and IEC ................. 38

Standard vent plug .................................... 40
C
Visual inspection ....................................... 37
Change the oil ...............................................39
Marking ......................................................... 13
Check the hose ..............................................38
Motor weights for IEC adapters .................... 28
Check the oil level .........................................37
N
Coolant ..........................................................34
Cooling cover .................................................30 nsd tupH ........................................................ 19
Correct use ....................................................10 O

Covers ...........................................................27 Option H66 .................................................... 23
D Overhaul ....................................................... 40
Disposal of materials .....................................41 P
F Painting the gear unit .................................... 32
Faults ............................................................. 69 Pulling devices .............................................. 22

Push-on gear unit.......................................... 23
G
R
Gear unit types ..............................................14
General overhaul ...........................................40 Radial shaft seal ........................................... 40
Re-grease the bearings ................................ 40
H
Re-greasing .................................................. 38
Hose fitting .....................................................68
Repairs .......................................................... 71
I
Roller bearing greases .................................. 57
Installation......................................................19
Running noises ............................................. 37
Installing the gear unit ...................................21
Running-in time ............................................. 35
Internet...........................................................71
S
L
Safety information ............................. 10, 17, 21
Leakage .........................................................70
Service .......................................................... 71
Long-term storage .........................................17
Service intervals ............................................ 36
Lubricant sensor ......................................33, 39
Shrink disc .................................................... 26
Lubricants ......................................................58
Standard motor ............................................. 28
M Standard vent plug ........................................ 40
Maintenance ..................................................71 Storage ......................................................... 17
Maintenance intervals ....................................36 Surface treatment
Maintenance work nsd tupH .................................................... 19
Changing the oil .........................................39 T
Check for running noises ...........................37
Tightening torques ........................................ 68
B 1000 en-5018 73
Transport .......................................................17 Visual inspection of hose .............................. 38
Type plate ......................................................16 W
V Warning information ...................................... 13
Visual inspection ............................................37
74 B 1000 en-5018
Key word index
B 1000 en-5018 75
Part-No. 6052802 / 5018

B 1000 - en Gear Units: Operating and Assembly Instructions

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B 1000 - en Gear Units: Operating and Assembly Instructions

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B 1000 – en

Read the operating and installation instructions

Table 1: Version list B 1000

Member of the NORD DRIVESYSTEMS Group

1 Safety information ..................................................................................................................................... 10

Table 1: Version list B 1000 ..................................................................................................................................... 3

1.1 Intended use

1.2 Do not make any modifications.

1.3 Performing inspection and maintenance work

1.4 Personnel qualification

1.5 Safety for particular activities

1.5.1 Check for transport damage

1.5.2 Safety information for installation and maintenance

1.6.1 Hazards when lifting

1.6.2 Hazards due to rotating parts

1.6.3 Hazards due to high or low temperatures

1.6.4 Hazards due to lubricants and other substances

1.6.5 Hazards due to noise

1.6.6 Hazards due to pressurised coolants

1.7 Explanation of markings

2 Description of gear units

2.1 Type designations and gear unit types

Gear unit types / Type designations

Table 2: Type designations and gear unit types

2.2 Type plate

Figure 1: Type plate (example) with explanation of type plate fields

3 Assembly instructions, storage, preparation, installation

3.1 Transporting the gear unit

3.3 Long-term storage

3.4 Preparing for installation

1 Standard vent plug

Figure 2: Activating the vent plug

Figure 3: Activating the vent plug

3.5 Installing the gear unit

3.6 Fitting hubs on the gear shafts

Figure 5: Example of a simple pulling device

Figure 6: Correct assembly of drive elements

3.7 Fitting push-on gear units

Figure 7: Applying lubricant to the shaft and the hub

Figure 8: Removing the factory-fitted closing cap

Figure 11: Dismantling using dismantling device

3.8 Fitting shrink discs

Figure 14: Hollow shaft with shrink disc

3.9 Fitting the covers

3.10 Fitting the covers

Figure 16: Removal and fitting of the cover cap

3.11 Fitting a standard motor

Maximum permitted motor weights

I Curved tooth coupling

3.12 Fitting the cooling coil to the cooling system

1 Cutting ring screw threads

Figure 18: Cooling cover

3.13 External oil-air cooler

3.13.1 Assembling the cooling system

Figure 19: Connecting the cooling system

3.13.2 Oil-air cooler electrical connection

3.14 Installation of an oil expansion tank, Option OA

Figure 20: Installing the expansion tank

3.15 Subsequent paintwork

4.1 Check the oil level

4.2 Activating the automatic lubricant dispenser

Figure 22: Adhesive label

4.3 Operation with lubricant cooling